Methods for forming woven undulated coil assemblies

ABSTRACT

Methods and apparatuses for forming a woven coil assembly (100), the coil assembly having adjacent superimposed linear portions (L1-L6, AL7-AL12) extending parallel to each other in a first area (A1) of the coil assembly, and adjacent superimposed linear portions (L7-L12, AL13-AL18) extending parallel to each other in a second area (A2) of the coil assembly, wherein a plurality of head portions (T) connect the linear portions of the first area (A1) to the linear portions of the second area (A2).

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a PCT national stage application entitled to andhereby claiming priority under 35 U.S.C. 365 and 371 to correspondingPCT application no. PCT/IB2016/052200, filed Apr. 18, 2016, entitled“Methods and Apparatuses for Forming Woven Undulated Coil Assemblies”,which in turn claims priority to Italian patent application nos.PI2015A000031, filed Apr. 30, 2015; PI2015A000032, filed Apr. 30, 2015;PI2015000033, filed Apr. 30, 2015 and PI2015A000034, filed Apr. 30,2015. Each of the foregoing applications is incorporated herein byreference in its entirety.

FIELD OF THE INVENTION

The present invention relates to a method and apparatus for forming coilassemblies of a known type, like woven undulated coil assemblies.

STATE OF THE ART

As is known, an undulated coil has adjacent linear portions extendingparallel to each other, and a plurality of turn portions for connectingthe ends of adjacent linear portions to each other.

The linear portions are inserted in slots of a stator core, whilst theturn portions protrude from respective end sides of the stator core. Thesection of the conductor from which the coil is formed may be circular,square or rectangular. The size of the section of the conductor isusually comparable to the width of the section of the slot of the statorcore. The conductors present in a slot are normally positioned oneadjacent to another in a radial direction of the stator core, i.e. alongan extension, which extends from a slot opening to the bottom of thesame slot.

For reasons of clarity, a coil formed from one conductor having theundulated configuration will be referred to as “a coil”, whilst a numberof coils having the aforementioned configuration, and which are woventogether, will be referred to as a coil assembly.

When examining the path of a conductor along the coil assembly which hasbeen formed according to a woven configuration, the linear portions ofone conductor are alternatively positioned above and below the linearportions of another conductor. This overlapping of a conductor isrepeated at a pitch distance along the coil assembly and for a certainnumber of undulations. The turn portions joining these linear portionsare positioned to be partially above and partially below turn portionsof other coils.

Solutions for producing woven coil assemblies of undulated coils havebeen described in U.S. Pat. Nos. 8,122,593, 6,376,961, EP1710996 andU.S. Pat. No. 6,140,735.

Stator cores wound according to these principles can be used indynamoelectric machines; in particular as components of traction motorsand energy generators of vehicles.

The woven coil assembly can be first produced as a flat coil assembly,i.e. a planar coil assembly. Successively, the coil assembly can betransformed into a cylindrical form to insert the linear portions in theslots of the core, or the linear portions can be inserted directly intothe slots of the core from the planar configurations. The turn portionsprotrude from the ends of the core after the linear portions have beeninserted in the slots.

Normally, the coil assembly thickness can be reduced by applyingcompression on the flat coil assembly. Prior to the compression, thelinear portions and turn portions need to be positioned with highprecision in view of the low allowable tolerances that exist during thesuccessive insertion operations in the core.

Furthermore, the production of woven coil assemblies has been mostly amanual operation, or a partially automatic using time consuming andcomplicated operations. Scarce success in these production attempts havebeen due to the high rate of inaccuracy in forming the coil assembly;particularly in forming the linear portions and the turns portionsaccording to the tolerances required in their positioning.

SUMMARY OF THE INVENTION

It is therefore an object of the present invention to provide a methodand an apparatus for manufacturing woven undulated coil assemblies,which overcome the drawbacks mentioned in the foregoing of the state ofthe art.

It is also an object of the present invention to provide a method and anapparatus for manufacturing woven undulated coil assemblies havinglinear portions and turn portions positioned with high precision.

It is a further scope of the invention to provide a method and anapparatus for manufacturing woven undulated coil assemblies with reducedproduction times with respect to the solutions of the state of the art.

It is another object of the present invention to provide a method and anapparatus for manufacturing woven undulated coil assemblies, which arehighly flexible, in other words capable of manufacturing woven coils andconductors having different geometries.

It is a particular object of the present invention to provide a methodand an apparatus for manufacturing woven undulated coil assemblies,which are completely automated.

These and other objects are achieved using the method and the apparatusfor forming woven coils as described in the independent claims.

Other characteristics of the inventions are described in the dependentclaims.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be now shown with the following description of anexemplary embodiment, exemplifying but not limitative, with reference tothe attached drawings in which:

FIG. 1 is a schematic representation of portions of undulated coils;

FIG. 2 is a schematic planar representation of a portion of a coilassembly formed according to the principles of the invention;

FIG. 3 is a schematic perspective view illustrating devices required forforming a coil assembly according to the invention;

FIG. 3a is a section view as seen from directions 3 a-3 a of FIG. 3;

FIG. 3b is a section view as seen from directions 3 b-3 b of FIG. 3;

FIG. 4 is a schematic perspective view similar to the view of FIG. 3illustrating devices required for forming a coil assembly according tothe invention in a certain stage of functioning;

FIG. 5 is a schematic perspective view similar to the view of FIG. 3illustrating devices required for forming a coil assembly according tothe invention in a further stage of functioning;

FIG. 5a is a view as seen from directions 5 a-5 a of FIG. 5;

FIG. 5b is a view similar to that of FIG. 3b in a different stage offunctioning;

FIGS. 6 to 14 are schematic views of various stages of functioningaccording to the principles of the invention as seen from a direction 6of FIG. 3;

FIG. 15 is a view similar to FIG. 4, although illustrating a secondembodiment of the invention;

FIGS. 16 to 20 are views similar to those FIGS. 6-14, althoughillustrating various stages of functioning of the second embodiment ofthe invention.

DETAILED DESCRIPTION OF THE INVENTION

FIGS. 1 and 2 show the constitution of a woven coil assembly 100. FIG. 1shows two separate undulated coil portions C1 and C2, which are used asa reference for explaining the woven coil assembly of FIG. 2.

A coil portion C1 is shown with dark shading, whilst a coil portion C2is shown without shading. In this example, each of the coil portions C1and C2 is formed of six wire conductors.

A portion of a formed woven coil assembly 100 consisting of twelve wireconductors is shown in FIG. 2. Coil assembly 100 has a flatconfiguration, which extends parallel to the plane P of the drawing ofFIG. 2. The result of FIG. 2 can be considered an interlacing of thecoil portions C1 and C2 of FIG. 1.

Considering more particularly the interlacing, in area A1 of coilassembly 100, six initial linear portions L1-L6 of coil portion C1 areoverlapped, or in other words superimposed, on six linear portionsAL7-AL12 of coil portion C2, therefore portions AL7-AL12 are not visiblein FIG. 2.

The distance between two adjacent superimposed linear portions isreferred to as the pitch (see PT in FIG. 2).

In area A2 of coil assembly 100, six linear portions AL13-AL18 of coilportion C2 are superimposed on six linear portions L7-L12 of coilportion C1, therefore linear portions L7-L12 are not visible in FIG. 2.

The transition between the various superimpositions occurs by means ofturns T, which represent the turn portions of the coil assembly as shownin FIG. 2.

Adjacent turn portions T overlap each other with an orderly progressionof succession. In fact, the overlap of the turn portions is such that itcauses the linear portions of any of the conductors to pass betweenoverlapping the linear portion of another conductor in area A1, to beingoverlapped by another linear portion of the same conductor in anadjacent area A2, as shown in FIG. 2.

This alternation of the linear portions being overlapped and thenoverlapping of the linear portions, with reference to one conductor,occurs constantly along the coil assembly for all the conductors, andrepresents the weaving or interlacing occurring.

In the example shown, the twelve conductors will have linear portionsand turn portions positioned according to the alternation of overlappingdescribed above.

According to the example of FIGS. 1 and 2, the linear portions of aspecific conductor are positioned along the coil assembly at distancesof 6 times the pitch distance, i.e. half the number of conductorsmultiplied by the pitch distance PT. Therefore as a general law, at adistances equal to half the number of conductor multiplied by the pitchdistance.

Area A1 is adjacent to area A2 and the two areas are delimited by aseparation distance SD equal to the pitch distance PT.

Areas A1 and A2 are repeated a predetermined number of times along thecoil assembly 100. At the end of the last of the areas A1, or A2 of theflat coil assembly 100, the conductors form leads like AL1-AL6respectively of coils C2, and initial leads I1-I6 of coils C1, which donot overlap as shown in FIG. 2.

However, when inserting the coil assembly 100 in the core of the stator,each of the leads I1-I6 of coil C1 can overlap a respective lead AL1-AL6of coil C2 during their insertion in the slots of the stator core.

The core of the stator, which receives the coil assembly of FIG. 2, willhave a number of slots proportional to the total number of linearportions that overlap. This total includes the linear portions ofinitial leads that overlap, as described previously. As a result, a slotof the stator core will have two linear portions that overlapaccommodated on another two linear portions that overlap, and also onother linear portions that overlap, depending on the number of areaslike A1 and A2, which have been foreseen in the coil assembly.

With reference to FIG. 3, a first embodiment is shown for forming theexample of a coil assembly of FIG. 2. More particularly, the exampleforesees twelve wire conductors of conductor group 12 fed throughrespective exits 23′ of conductor supply store 23. Each conductor of thegroup of conductors 12 can be fed from a respective conductor supplyreel (not shown) to exits 23′. Furthermore, along direction X, each ofthe wire conductors of group 12 passes through a respective seat ofgroup of seats 24 of guide unit 36, as shown in FIG. 3. The seats ofgroup 24 are twelve, each being aligned with a seat of conductor storeexits 23. Therefore, the number of seats of group 24 is equal to thenumber of conductors of group 12.

The seats of group 24 are parallel to each other to cause conductors ofgroup 12 to remain parallel to each other and to be separate from eachother by a same pitch distance PT.

Feeding the conductors of group 12 in direction X can be seen as being afeeding of the conductors in direction X in a same plane P, whichcontains the twelve conductors. Orthogonal directions to X will be the Ydirection, and the Z direction, as shown in FIG. 3. Directions X′, Y′and Z′ are directions opposite to directions X, Y, Z, respectively.

A first unit or holding device 37 is located down stream of guide unit36 in the feeding direction X of the conductors. First holding unit 37is provided with a first plate 38, or support member, having group ofseats 39 which are open towards a second plate 51, or cover member. Thesecond plate 51 covers the first plate 38 (see also FIG. 3a ).

The seats of group 39 are twelve and are aligned with those of guideunit 36. Furthermore, the seats of group 39 are parallel to each other,and have the same separation pitch PT. First holding unit 37 is locatedso that seats of group 39 are aligned with seats of group 24 in order toachieve a travel of conductors of group 12 through the seats of guideunit 36 and first holding unit 37 without bending conductors of group12.

A second device or holding unit 55 is located down stream of firstholding unit 37 in the feeding direction X of the conductors. Secondholding unit 55 is provided with a first plate 56, or support member,having group of seats 59, which are open towards a second plate 58, orcover member which covers the first plate 56 (see also FIG. 3b ).

Seats of group 59 are parallel to each other and aligned with the sameseparation distance PT described in the foregoing for the seats of group24 of guide unit 36.

Second holding unit 55 is located so that seats of group 59 are alignedwith seats of group 39 of first holding unit 37 in order to achieve atravel of conductors of group 12 through the seats of first holding unit37 and second holding unit 55 without bending conductors of group 12.

First plate 38 and second plate 51 of first holding unit 37 areassembled together to allow passage of the conductors in directions Xand X′ through seats of group 39 and without causing unwanted movementsin transverse directions Y and Y′ and Z and Z′, and also for locking theconductors in directions X and X′ when required.

First plate 56 and second plate 58 of second holding unit 55 areassembled together to allow passage of the conductors in the feedingdirection X to reach the ends of seats of group 59 without causingunwanted movements in directions Y and Y′ and Z and Z′, and also forlocking the conductors in directions X and X′ once the conductors havereached a required position at the ends of the seats of group 59.

The resulting situation of conductors of group 12 which have been fedthrough guide unit 36, first holding unit 37, and second holding unit 55is shown in FIG. 3.

A clamp device, not shown, can place the conductors on the paths and inthe groups of seats described with reference to FIG. 3. The clamp isable to hold the ends of the conductors at the pitch distance PT. Theclamp device moves in direction X to pull the conductors from the supplystore 23. When the clamp device moves in direction X, a conductor isaligned with a specific seat of plate 36′, plate 38 and plate 56. Duringthis movement, plate 36″, plate 51 and plate 58 have been removed toallow the conductors to access the seats when the clamp is moved indirection Z′. Once the conductors are located in the seats, plate 36″,plate 51 and plate 58 can be relocated, as shown in FIG. 3.

FIG. 3a shows the section view of first holding unit 37 having group ofseats 39 of first plate 38, where in each seat a conductor of group ofconductors 12 is located. Second plate 51 covers the first plate 38. Theunderside of plate 51 can be in engagement with a predetermined pressureon the conductors to exert a clamping action when holding is required.If the conductors need to move though the seats, then the pressure canbe reduced.

FIG. 3b shows the section view of second holding unit 55 having firstplate 56 with group of seats 59, where a conductor is located in eachseat, as shown. Similarly, second plate 58 covers the first plate 56.The underside of plate 58 can be in engagement with a predeterminedpressure on the conductors to exert a clamping action when holding isrequired. If the conductors need to move though the seats, then thepressure can be reduced.

Second plate 58 is provided with extension 58′. The width W of theextension is such that the underside 58″ of the extension 58′ can coverand engage half the number of conductors (six conductors in the case ofthe example) of group of conductors 12, at a certain stage of theforming of the coil assembly.

FIGS. 6-14 are planar representations parallel to plane P showing asequence of steps for forming the woven coil assembly of FIG. 2 startingfrom the condition of FIG. 3.

FIG. 6 shows the situation of FIG. 3

A successive step of the coil forming solution is shown in FIG. 7, wheresecond holding unit 55 has moved in directions Y of plane P to causeconductors of group 12 to become inclined between second holding unit 55and first holding unit 37. In particular, during the movement of thesecond holding unit 55 a first portion 1P′ of conductors 12 (see FIG. 6)is bent.

For the example shown, the distance of the movement in direction Y isequal to six times the pitch PT. During the movement of second holdingunit 55 in direction Y, guide unit 36 and first holding unit 37 can bemoved in direction X to avoid excessive strain on the conductors ofgroup 12.

This step of FIG. 7 results in the formation of the inclined portion IC1of portion 1P′ of conductors of group located between second holdingunit 55 and first holding unit 37.

A successive step of the coil forming solution is shown in FIG. 4 andFIG. 8, where second holding unit 55 has moved further in directions Yof plane P, and at the same time first holding unit 37, which is holdinga second portion of conductors 2P′, is moved in direction Y for the samedistance. This distance is equal to six times the pitch PT. The furthermovement in direction Y causes conductors of group 12 to become inclinedbetween first holding unit 37 and guide unit 36, i.e. of a third portionof conductors 3P′, thereby forming second inclined portion IC2 as shownin FIG. 8. Guide unit 36, which is positioned upstream of portion 3P′,positions a fourth portion 4P′. Guide unit 36 is moved in direction X toavoid straining the conductors of group 12, when second holding unit 55and first holding unit 37 are moved in direction Y.

In addition, as shown in FIG. 4 and FIG. 8, a bending plate 80 ispositioned between first holding unit 37 and second holding unit 55.Preferably, bending plate 80 is located proximate to second plate 51 offirst holding unit 37, with bending edge 80′ positioned transverse andperpendicular to feeding direction X, as shown in FIGS. 4 and 8.

More particularly, bending edge 80′ can be in engagement with theinclined portion IC1 of conductors of group 12 located between firstholding unit 37 and second holding unit 55. Preferably, the engagementcan occur approximately at the middle of the inclined portion IC1, asshown in FIGS. 4 and 8.

The next stage of the coil forming solution is shown in FIG. 9, whereplate 56 of second holding unit 55 has been rotated according to arrow Aaround bending edge 80′. Bending edge 80′ is aligned with axis A′ andorthogonal to the feeding direction X. Prior to the rotation, in thisstage around axis A′, plates 51 and 58 are respectively removed from thefirst holding unit 37 and the second holding unit 55. Possible solutionsfor rotations around bending edge 80′ can be either that plate 56 isrotated itself around bending edge 80′, or that plate 56 is rotatedaround a middle axis R-R of second holding unit (see FIG. 4) forrotation A, and at the same time plate 38 moves in direction X anddirection Z′. This second combination of motions achieves that bendingedge 80′ remains in engagement with the middle of the inclined portionIC1 during the rotation A around the middle axis R-R of plate 56.

This combination of motions results in a rotation around the bendingedge 80′.

At a predetermined position of the rotation around bending edge 80′,bending plate 80 is removed to allow plate 56 to become close to plate38, and at the same time to be located over plate 38, as shown in FIGS.5 and FIG. 9.

With reference to FIGS. 1, 2 and 5 a, the resulting situation is thatleads AL1-AL6 of the coil assembly have been formed together with areaA1 consisting of linear portions L1-L6 overlapping linear portionsAL7-AL12, and also linear portions L7-L12. This result is visible inFIGS. 5 and 5 a, where linear portions L7-L12 remain uncovered andpositioned on one side of plate 56.

Successively, as shown in FIG. 10, guide unit 36 and overlapping plates56 and 38 can be moved in direction X simultaneously and for sameamounts to draw further lengths of conductors of group 12 from theirrespective wire conductor supply stores. This also obtains that inclinedportion IC2 becomes aligned with the position where bending plate 80 isapplied, as shown in FIG. 8.

In FIG. 11, plate 38 has been moved in direction Z′ to become free fromthe conductors and has been translated in direction Y′ to return to theposition in alignment with guide unit 36. In this way plate 38 canreturn to form first holding unit 37 with plate 51 repositioned as shownin FIG. 12.

In FIG. 12, guide unit 36 and first holding unit 37 have been moved indirection X′ along the conductors of group 12 to reach the position ofFIG. 7.

Also with reference to FIG. 12, plate 56 has been rotated with rotationB to pass from being above the portion of formed coil assembly to beingbelow as shown. In addition, plate 56 has been moved in direction Y′ for6 pitch distances to the original alignment position of FIG. 7.

When plate 56 is below the coil assembly and in alignment with thelinear portions as shown in FIG. 12, plate 56 can be moved in directionZ to receive the aligned linear portions of the coil assembly.

More particularly, with reference to FIGS. 12, 13 and 5 b, plate 56 hasmoved in direction Z to receive area A1 consisting of linear portionsAL7-AL12, overlapped by linear portions L1-L6, and linear portionsL7-L12, whilst leads AL1-AL6 of the coil assembly extend beyond plate56.

In a comparison between FIG. 5a and FIG. 5b , it is to be noted that inFIG. 5b there has been a displacement of plate 56 in direction Y′ for 6pitch distances.

FIGS. 13 and 5 b show that plate 58 has been repositioned over plate 56and that the resulting situation can be a successive start conditionsimilar to that of FIG. 7.

A following series of stages like those of FIGS. 8-12 can beaccomplished to continue forming the coil assembly. The end result willbe that of FIG. 14, where bending has occurred once again around bendingedge 80′ for second inclined portion IC2.

FIG. 14 is a situation like that of FIG. 9, although with a furtherportion of the coil assembly that has been formed.

In fact, in the situation of FIG. 14 and with reference to FIG. 2,linear portions AL13-AL18 overlap linear portions L7-L12 to form area A2and linear portions L13-L18 will be seated in seats of plate 38 withoutbeing overlapped.

Linear portions L13-L18 will later be overlapped by linear portionsAL19-AL24 as a result of rotating with the bending edge 80′ engagedagainst inclined portion IC3.

It will be appreciated that the coil assembly can be completed bycreating further inclined portions like IC1, IC2, IC3 and rotatingagainst bending edge 80′, like has been described in the foregoingsequence.

A second embodiment of the invention for forming the coil assembly ofFIG. 2 is shown in FIG. 15, where group of conductors 12 reach firstholding unit 37 without passing through a guide unit like 36. In thesecond embodiment, second holding unit 55 is present and has functionssimilar to those of the second holding unit 55 of the first embodiment.

FIGS. 16-20 are stages similar those of FIGS. 6, 7 and 9 to form theresult of the coil assembly which has been described with reference toFIG. 9.

In the second embodiment a second inclined portion has not been formedprior to bending the first inclined portion IC1 around bending edge 80′,like has been described previously for the first embodiment withreference to FIG. 8.

In particular, in this embodiment, during bending of portion 1P ofconductors 12 which forms the inclined portion IC1, the portion 2P,which is upstream along the feeding direction X, is positioned and beingheld in the holding device 37. As shown schematically in FIG. 19, therotation of the portion of the first portion 1P occurs around an axis A″placed substantially in the middle of the first portion 1P, andperpendicular to the feeding direction X.

Successively, there is feeding of the conductors in the feedingdirection X, which achieves a third portion 3P of the conductorspositioned between the holding device 37 and the plate 56 (FIG. 20).

In particular, the third portion 3P of the conductors is locateddownstream of a fourth portion 4P of the conductors, positioned in theholding device 37 in FIG. 20. The third portion is thus bent and thebent portion is successively rotated around axis A″, which obtains arotated portion of conductors oriented in a direction opposite to thefeed direction X.

FIG. 21 is a successive stage after a second rotation around a secondinclined portion. The portion of the coil assembly formed in FIG. 21 islike that of FIG. 14. FIG. 21 show that portion T1 of the formed coilportion bears on straight portion ST1 of group of conductors 12. Thiswill maintain portion T1 above plane P and with a certain incline.

Portion T1 can be repositioned in plane P after a successive series ofsteps which form the next extra portion of the coil assembly. In thissituation, portion T1 will have been shifted to an area, where portionT1 is no longer bearing on group of conductors 12. In this condition ofportion T1, portion T1 can be pressed to return it into plane P.

The foregoing description exemplary embodiments of the invention will sofully reveal the invention according to the conceptual point of view, sothat others, by applying current knowledge, will be able to modifyand/or adapt for various applications such embodiment without furtherresearch and without parting from the invention, and, accordingly, it istherefore to be understood that such adaptations and modifications willhave to be considered as equivalent to the specific embodiments. Themeans and the materials to realise the different functions describedherein could have a different nature without, for this reason, departingfrom the field of the invention. It is to be understood that thephraseology or terminology that is employed herein is for the purpose ofdescription and not of limitation.

The invention claimed is:
 1. A method for forming a woven coil assembly,the coil assembly having adjacent superimposed linear portions extendingparallel to each other in a first area of the coil assembly, andadjacent superimposed linear portions extending parallel to each otherin a second area of the coil assembly, wherein a plurality of headportions connect the linear portions of the first area to the linearportions of the second area, the method comprising: feeding a pluralityof conductors for a predetermined length in a feeding direction parallelto each other and substantially parallel to a plane; bending a firstportion of the length of the plurality of conductors according to apredetermined orientation such that the plurality of conductors of thefirst portion are parallel to each other, oriented according to an angleof orientation, and positioned in the feeding direction downstream of asecond portion of the length of the plurality of conductors that havenot been bent; bending a third portion of the length of the plurality ofconductors according to the predetermined orientation such that theplurality of conductors of the third portion are parallel to each other,oriented according to the angle of orientation, and positioned in thefeeding direction downstream of a fourth portion of the length of theplurality of conductors that have not been bent, the fourth portionpositioned in the feeding direction upstream of the first portion; andprior to bending a further portion according to the predeterminedorientation of the length of the plurality of conductors, rotating aportion of the first portion about an axis positioned substantiallymidway along the first portion and perpendicular to the feedingdirection such that the rotated portion of the first portion ofconductors are parallel to each other in a direction opposite to thefeeding direction.
 2. The method of claim 1, further comprising rotatinga portion of the third portion about an axis positioned substantiallymidway along the third portion and perpendicular to the feedingdirection such that the third portion of conductors are parallel to eachother in a direction opposite to the feeding direction.
 3. The method ofclaim 2, further comprising bending a fourth portion of the length ofthe plurality of conductors according to a predetermined orientation. 4.The method of claim 3, wherein the steps of claims 1 to 3 are repeated apredetermined number of times to form a corresponding number of firstareas and second areas to complete the coil assembly.
 5. A method forforming a woven coil assembly, the coil assembly having adjacentsuperimposed linear portions extending parallel to each other in a firstarea of the coil assembly, and adjacent superimposed linear portionsextending parallel to each other in a second area of the coil assembly,wherein a plurality of head portions connect the linear portions of thefirst area to the linear portions of the second area, the methodcomprising performing: a first step of feeding a plurality of conductorsfor a predetermined length in a feeding direction parallel to each otherand substantially parallel to a plane; a second step of bending a firstportion of the length of the plurality of conductors according to apredetermined orientation, the plurality of conductors of the firstportion after bending being parallel to each other, oriented accordingto an angle of orientation, and positioned in the feeding directiondownstream of a second portion of the length of the plurality ofconductors that have not been bent; a third step of rotating a portionof the first portion about an axis positioned substantially midway alongthe first portion and perpendicular to the feeding direction, therotating positioning the rotated portion of the first portion ofconductors parallel to each other in a direction opposite to the feedingdirection; a fourth step of feeding the plurality of conductors for apredetermined length in a feeding direction parallel to each other andsubstantially parallel to a plane; a fifth step of bending a thirdportion of the length of the plurality of conductors according to apredetermined orientation, the plurality of conductors of the thirdportion after bending being parallel to each other, oriented accordingto an angle of orientation, and positioned in the feeding directiondownstream of a fourth portion of the length of the plurality ofconductors that have not been bent; and a sixth step of rotating aportion of the third portion about the axis positioned substantiallymidway along the third portion and perpendicular to the feedingdirection, the rotating positioning the rotated portion of the thirdportion of conductors parallel to each other in a direction opposite tothe feeding direction.
 6. The method of claim 5, wherein the steps ofclaim 5 are repeated a predetermined number of times to form acorresponding number of first areas and second areas to complete thecoil assembly.
 7. The method of claim 5, wherein portions of the turnsare repositioned in the plane.